58
Supplementary Owner's Handbook Renault Master 1-Way Tipper Feb 2013 on
Supplementary Owner's Handbook
Renault Master 1-Way Tipper
Feb 2013 on
2
The illustrations, technical information, data and descriptions contained in this publication, were correct at the
time of going to print. VFS (Southampton) Ltd reserve the right to make any changes necessary in line with
continuous development and improvement.
No liability can be accepted for any inaccuracies or omissions in this publication, although due care has been
taken to make it as complete and accurate as possible.
The publication may not be duplicated, reprinted, stored in a data processing system or transmitted by
electronic, mechanical, photographic or other means, or recorded, translated, edited, abridged or expanded
without the prior written consent of VFS (Southampton) Ltd.
The same also applies for parts of this manual and their use in other publications.
© Copyright 2013, Issued by VFS (Southampton) Ltd. Part No: VFS02-22-209B
Feb 2013
3
Table of Contents
Introduction Page Fuses Page
About this handbook 4 Fuse Locations 49
Parts and Accessories 5
Warranty 5 Vehicle Care
Safety First 6 Cleaning the Exterior 50
Repairing Minor Paint Damage 51
Quick Start
Quick Start 7-18 Towing
Tailboard Protection 52
Tipper Controls
Tailboard 19-24 Fault Finding
Sideboards 25-27 Fault Finding 53-54
Isolation Switch 28
Pendant Controller 29 Lighting
Emergency Stop Switch 31 Changing a Bulb 55
Warning Sounder 32
Body Prop 33-34 Vehicle Identification
Vehicle Identification 56
Load Carrying
General Information 35 Technical Specifications
Loading 35 Medium Wheelbase Single Cab 57
Load Distribution 36 Long Wheelbase Double Cab 58
Load Retention and Sheeting 37-38
Tipping
Tipping 39-43
Maintenance
Daily Driver Checks 44-45
Monthly Maintenance Checks 46
Annual Maintenance Checks 47
Hydraulic Oil Level Checks 48
4
Introduction
ABOUT THIS HANDBOOK
This supplementary owner’s handbook must be referred to in addition to the standard
Owner’s Handbook. Read and understand both manuals and familiarise yourself with
the vehicle before operating the vehicle on the road.
Note: This handbook only details the features on the Tipper that are not covered in the
standard owners handbook, therefore it is imperative that this supplementary
handbook is kept with the standard Owner’s Handbook.
Note: Always use and operate your vehicle in line with all applicable laws and
regulations.
Note: Pass on this handbook when selling your vehicle; it is an integral part of the
vehicle.
SYMBOLS IN THIS HANDBOOK
You risk death or serious injury to yourself and others if you do not follow the
instructions highlighted by the warning symbol.
When you see this symbol, read and follow the relevant instructions in this
handbook.
You risk damaging your vehicle if you do not follow the instructions highlighted
by the caution symbol.
WARNING
CAUTION
5
Introduction
PARTS AND ACCESSORIES
Spare parts and Accessories are available from: VFS (Southampton) Ltd,
Unit 8, Barton Park Industrial Estate, Chickenhall Lane, Eastleigh SO50 6RR
Tel: 023 8065 1704 Fax: 023 8062 0999 Email: [email protected]
Detailed Spare Parts and Accessories can be found in the relevant section on-line at
www.vfs.co.uk
WARRANTY
Full warranty exists on all parts and workmanship associated with the tipper body
conversion for 3-years / 100,000 miles. Warranty is only valid if the Tipper is operated
in accordance with the Supplementary Owner’s Handbook and current Road Traffic Act
Legislation.
Warranty claims for parts associated with the Tipper body conversion should be made
direct to VFS Ltd.
VFS (Southampton) Ltd.
Unit 8 Barton Park Industrial Estate
Chickenhall lane
Eastleigh
Hants
SO50 6RR
Tel: 023 8065 1704
Fax: 023 8062 0999
Email: [email protected]
6
Introduction
SAFETY FIRST!
Tipping is a potentially hazardous operation. It is essential that all operators
fully understand the procedures detailed in this handbook and are aware of the
Tipper controls on the vehicle. Health and Safety legislation must be strictly
applied. UK Construction & Use Regulations must be observed when
operating the vehicle on the public highway.
The basis for Health and Safety law in the UK is the Health and Safety at Work Act
1974 and its amendments. However certain EU Law is now applicable; all of which
must be complied with before, during and after the use of this vehicle and the Tipper
bodywork supplied with it. The Tipper bodywork supplied with this vehicle is recognised
as a machine, therefore Health and Safety legislation applicable to machinery must be
recognised in addition to general Health and Safety law.
It is the responsibility of the Driver, Owner and/or Operator to establish what Health
and Safety legislation applies when using this vehicle and that only persons trained
and qualified in line with that legislation be allowed to use this machine.
Depending on the circumstances and the territory that the vehicle is being used, other
legislation may apply. Always check that existing legislation has not been updated or
superseded, and whether new legislation has been introduced.
WARNING
7
Quick Start
This quick start guide is intended to refresh operators of the control layout, operation
and loading of the vehicle only after this handbook has been read and understood.
Tipper Controls and Layout
Isolation Switch – LHS of Tipper Subframe
Isolator Off Position
Isolator On Position
8
Quick Start
Tipper Pendant Control – LHS of Passenger Seat
Slide Pendant Control rearward to release from Holster.
Press to Raise Press to lower
9
Quick Start
Emergency stop
Press to engage Rotate clockwise to release
The Emergency Stop Switch is located on the top of the Pendant Control.
Press Emergency Stop Switch Button to cease all tipping functions.
Rotate Button clockwise and allow button to spring out to re-set.
Clear any danger before re-setting Emergency Stop
WARNINGS
10
Quick Start
Controls Layout – Body
Tip-Over Latch releases Tailboard for ’Tip-over’ function.
Tailboard Lower Latch Releases tailboard for ‘Tip-through’ function.
Sideboard Release Latch releases Sideboard for loading and unloading.
Close Boards and secure Latches and Release Levers before driving.
Quick Start
WARNINGS
11
Quick Start
Loading the Tipper
Ensure the load is uniformly distributed across the Tipper bed.
All loads must be secured and restrained before operating the vehicle on the
public highway. Failure to adequately restrain the payload presents a hazard to
other road users and is in contravention of the UK Construction and Use
Regulations.
Do not exceed 50mph if any equipment or loads are placed on the headboard
gantry. Maximum gantry load – 250Kg
Do not overhang plank or sheet material forward of the headboard.
WARNINGS
12
Quick Start
Load Distribution
CORRECT LOAD DISTRIBUTION
INCORRECT LOAD DISTRIBUTION
13
Quick Start
Load Retention – Load Anchorage Points
Used for non-fluid loads. Always ensure that all items are secured before attempting to
drive the vehicle. Do not tip with the items lashed down to the anchorage points.
Vehicle Mass (GVM) or individual front and rear axle capacities. Refer to the
Vehicle identification section in the Owner’s Handbook.
WARNING
14
Quick Start
Load Sheeting – Sheeting Hooks
It is recommended that all 'Fluid' loads such as Sand, Gravel, soil, wood chippings etc
are sheeted for the benefit of other road users.
Sheeting hooks and Gantry lashing eyes are rated at 25Kg maximum each.
Do not use sheeting hooks to anchor loads.
WARNING
15
Quick Start
Tailboard configuration
Dependent upon the type of load being tipped the dual mode tailboard can be
configured to open in one of two ways:- establish correct mode before attempting to tip.
Top Hinged (Tip-Thru) – best suited for ‘Fluid’ loads such as sand, gravel, crushed
concrete, type 1, soil, wood shavings etc.
Bottom Hinged (Tip-Over) – best suited for loads consisting of one or more large
individual items for example logs, tree cuttings, white goods, furniture etc.
t
16
Quick Start
Tailboard configuration contd.
Bottom Hinged mode - Always ensure sufficient clearance for the tailboard to
hang without touching the ground, a minimum of 12" (300mm) is
recommended with the Tailboard in the lowered condition - body fully laden
and in the lowered position.
If a tow bar has been fitted, ensure that the tailboard has been fitted with a
protective guide (see Towing) to prevent it from jamming on the tow hitch. If a
guide is not installed the tailboard may be damaged.
Bottom Hinged mode – Vehicle rear lights and hazard lights will be obscured,
always deploy additional warnings to other road users and minimise the
amount of time the board is lowered, return board to the shut position
immediately after the tip is completed.
17
Quick Start
Tipping
Preparation:
Apply handbrake and switch on hazard warning lights.
Ensure the ground bearing the weight of the vehicle is level and is firm.
Check that the area surrounding the vehicle is free from personnel, equipment
and livestock, except for an assistant specifically tasked to guide you to the
area where the load is to be tipped.
Ensure the area surrounding the vehicle is suitably illuminated. (night
operation)
Check overhead clearance for overhead cables and power lines, abort tip or
reposition vehicle if there are any overhead cables within the vicinity.
Operation:
To Raise:-
Open the tailboard.
Switch the Tipper Isolation Switch to the ‘ON’ position.
Control the tip using the Hand Controller as described in the Tipper Controls
section of this manual.
Press the RAISE button to raise the body to the required height to either tip
part or the entire load. Tipping can be stopped at any time by releasing the
RAISE button. A sounder will be active when the RAISE button is pressed and
throughout tipping operations and until body is lowered and stowed.
18
Quick Start
Tipping continued…
To lower:-
Press the LOWER button to lower the body. Keep depressed until the warning
sounder ceases
Close the tailboard ensuring that it is securely locked.
Switch the Tipper Isolation Switch to the ‘OFF’ position.
A warning triangle or similar devices are permitted to be placed in the road
to warn of a temporary obstruction.
Ensure Tailboard is closed and locked before driving the vehicle.
Never drive the vehicle with the Tailboard in the lowered position.
Vehicle side lamps must remain on during loading/unloading through the
hours of darkness or poor visibility.
Tailboard in lowered position obscures vehicle rear lights.
Avoid lowering the tailboard when stationary on the Public Highway.
Temporary obscuration during loading/unloading is acceptable providing
other road users are warned of an obstruction in the road by use of a
Warning Triangle. Or a minimum of four traffic cones or pyramids.
CAUTION
WARNINGS
19
Tipper Controls
Dual Mode Tailboard
Description:
The tailboard is designed to operate in two different configurations dependant upon the
type of load, the configuration is determined by the operator prior to tipping. The
following guidelines are to enable the operator to identify and apply the correct
configuration before tipping.
Location:
The tailboard is mounted at the rear of the body, located by four latches/pivots. Two
positioned on the upper edge of the board, and two located on the lower edge. The
lower latch is remotely operated by a yellow handle mounted below the tipper bed to
the offside rear, behind the rear wheel fender.
Purpose:
To safely discharge the payload from the rear aperture of the body.
To provide restraint for fluid loads only. All loose loads must be restrained
using the load lashing rings provided. The tailboard is not designed to prevent
un-restrained loads from penetrating or bursting the tailboard.
20
Tipper Controls
Dual Mode Tailboard continued…
Top-Hinged or Tip-Thru: Recommended for 'Fluid' loads:
Sand.
Gravel
Crushed concrete
Type 1
Dry topsoil
Wood shavings
Bottom-Hinged or Tip-Over: Recommended for loads consisting of one or more large
individual items:-
Logs
Tree cuttings
Clay.
White goods
Furniture
NB: If in doubt, always use the Tip-over mode.
21
Tipper Controls
Top Hinged / Tip-thru mode:
If the load begins to jam or choke in the rear aperture created by the
tailboard hinging from the top, lower the body fully and clear the obstruction.
Do not continue to tip when a jam occurs.
Bottom Hinged / Tip-over mode:
Always ensure that there is sufficient clearance for the tailboard to hang
without touching the ground, a minimum of 12" (300mm) is recommended
with the Tailboard in the lowered condition – body fully laden and in the
lowered position.
If a tow bar has been fitted, ensure that the tailboard has been fitted with a
protective guide (see Towing) to prevent it from jamming on the tow hitch. If a
guide is not installed the tailboard may be damaged.
WARNINGS
22
Tipper Controls
Dual Mode Tailboard continued…
Use: Tip-Thru mode: -
To open tailboard:
Locate the yellow remote operating handle and pull outward and forwards in an arc
until it stops.
To close tailboard:
Brush down the lower edge and
outer vertical edges of the body to
ensure the tailboard can close
without jamming.
Push the tailboard closed.
Holding the tailboard closed with one
hand, return the remote release lever
to the shut position.
Check the lower remote release handle Is locked and the tailboard is secure.
23
Tipper Controls
Dual Mode Tailboard continued…
Use: Tip-over mode:
To open tailboard:
Hold the top of the tailboard with one
hand, with the other hand use an index
finger or forefinger to release the latch,
by first pulling up to approximately
90 degrees from the vertical.
Using the palm of your hand push up on
the handle until it is almost vertical and
the latch is released.
Repeat the action for the other latch.
Maintain pressure on the tailboard until
it is safe to lower gently.
To close tailboard:
Brush away debris from the tailboard,
specifically the edges and two upper
latch pins. Clear the vertical edges of
the body corner and horizontal rear
edge of the tipper bed.
Grab the lower edge of the tailboard
with both hands and rotate upwards to
its closed position.
24
Tipper Controls
Dual Mode Tailboard continued…
Return the latches to their closed position
by pushing down on the handle with the
palm of one hand and supporting the
the tailboard with the other. Maintaining
pressure on the tailboard repeat for 2nd
latch.
Grasp tailboard by the top edge and pull
to ensure it is secure.
25
Tipper Controls
Sideboards
Description:
The sideboards are made from tough lightweight extruded aluminium held in place by
two latches per side, locking the sideboard to the headboard and rear corner pillars.
Location:
Near and offside of vehicle.
Purpose:
To provide restraint for fluid loads only. All loose loads should be restrained using the
load lashing rings provided. The sideboards are not designed to prevent un-restrained
loose loads from penetrating or bursting the sideboards.
Use:
Sideboards can be lowered to aid the manual or mechanical loading / unloading of
non-fluid material.
To open sideboard:
Remove sheeting if the load is sheeted remove or tie-off tarpaulin safely.
Visually check that the load is not exerting a force on the sideboard.
26
Tipper Controls
Sideboards continued…
Release the front latch by pulling handle up and pushing up to the vertical.
Release the rear latch whilst holding the top of the sideboard with one hand,
and releasing latch with the other hand.
Maintain pressure on the sideboard until it is safe to lower gently.
27
Tipper Controls
Sideboards continued…
To close sideboard:
Brush away all debris between the sideboard and the edge of the Tipper
bed, including the vertical faces at the headboard and rear corner pillar.
If any resistance to closing the board is felt, lower the board and remove the
debris – do not force it closed.
Lift the sideboard and rotate it until shut, holding the top of the board with
one hand, grasp one latch in the palm of the hand and push the latch
handle home. Repeat for other latch.
Grasp sideboard by the top edge and pull to ensure the sideboard is secure.
28
Tipper Controls
Isolation Switch
Description:
The Tipper Isolation Switch provides Electrical isolation to both the electric and
hydraulic systems found on the tipper.
Location:
The switch is located on the left hand side of the Tipper Subframe.
Purpose:
To safely isolate the Tipper electric and hydraulic systems from the vehicle when the
tipper is not in use.
Use:
The isolation switch must be set to ‘OFF’ when performing any maintenance
tasks with the bed raised and propped.
Do not drive the vehicle with the Tipper Isolation Switch in the ‘ON’ position
WARNING
29
Tipper Controls
Tipper Pendant controller
Description:
A Hand Controller with single rocker switch and Emergency stop
button which allows control of the raise/lower function of the body
is attached to vehicle via an expanding coiled Wanderlead.
Location:
The Tipper Hand Control is located on the side of the passenger seat in a dedicated
holster accessed from the passenger door area.
Purpose:
The Tipper Hand Control enables the operator to raise and lower the tipper bed.
Use:
The Tipper Hand Control can be operated from the passenger door area adjacent to
the passenger seat.
To perform tipping operations ensure handbrake is applied, transmission is in neutral
and engine is running. Tipping will not proceed without engine running.
30
Tipper Controls
Tipper Pendant controller continued…
To Raise Body…
Release tailboard.
Switch Isolation Switch to ON position
Press RAISE button on Pendant Control.
Release RAISE button at any time to cease raising
Continue pressing RAISE until body is fully raised
Release RAISE button when body is fully raised.
To lower body…
Press LOWER button on Pendant Control
Body lowers with external sounder operating.
Release LOWER button at any time to cease lowering.
Continue pressing LOWER until body is fully lowered.
Keep button pressed for 5 seconds to purge system of hydraulic pressure.
Check body is fully stowed
Emergency Stop…
At any time, pressing the Emergency Stop Button can cease all Tipper functions.
Ensure it is safe to proceed and release emergency stop button by twisting it
clockwise.
31
Tipper Controls
Emergency Stop Switch
Description:
The Emergency Stop Switch ceases all Tipper operations.
Location:
The Emergency Stop Switch is located on the top of the Tipper Pendant Control.
Purpose:
In emergency situations when the switch is activated all Tipper functions cease,
until the switch is reset.
To Activate:
Press in with finger or palm of hand.
To Release:
Rotate clockwise and allow button to spring out.
32
Tipper Controls
Warning Sounder
Description:
The Warning Sounder indicates when the Tipper is in use.
Location:
The Warning Sounder is located on the Tipper subframe.
Purpose:
The Warning Sounder, indicates when the tipping operation has commenced and the
body has been raised or is being lowered.
Use:
The Warning Sounder functions automatically.
If the Warning Sounder does not operate during normal tipping functions, stop
immediately and refer to the fault diagnosis section.
33
Tipper Controls
Body Prop
Never Stand or Work underneath an un-propped body.
Description:
A body prop is a safety device that is provided to ensure the safety of personnel
carrying out routine checks and maintenance of components and structures
underneath the body.
Location:
The body prop is an integral part of the subframe and is stowed on the
outside of the offside subframe.
Purpose:
To provide a safe means to mechanically support the body in a raised position.
Use:
Whenever there is a requirement to work or stand underneath the body.
Do not leave the vehicle with the body raised and propped for any length of
time. The protective oil film on the ram will evaporate, drain away or be
washed away. Corrosive elements may erode the highly finished surface of the
ram, which in turn could lead to damage of the ram seals, resulting in potential
oil leaks.
WARNING
WARNING
34
Tipper Controls
Body Prop continued…
How to deploy the Body Prop:
Park the vehicle on a firm level
surface and apply the handbrake.
Raise the Tipper bed.
Raise the body prop by pulling
up on the handle.
Rotate the body prop past the
vertical until it stops.
Lower the body until it rests on
the prop.
Turn the Tipper Isolation
Switch to the 'OFF' position.
Remove the keys from the vehicle
ignition.
35
Load Carrying
General Information
All loads must be secured and restrained before operation on the public
highway. Failure to adequately restrain the payload will present a hazard to
other road users and is in contravention of the UK Construction and Use
Regulations.
The Tipper is designed to carry bulk loads of which there are two distinct types:
'Fluid' Bulk loads are loads that act similar to a fluid once in motion, for example:
Sand, Gravel, Type 1 Aggregate, Hardcore, Topsoil, Wood Chippings.
Non-Fluid Bulk loads, for example:
Palletised or wrapped building materials (bricks, tiles, thermal blocks), Timber,
Sheet material (plywood, plasterboard etc. Machinery, White goods, Furniture.
Loading
Prior to loading ensure that the Tipper is fully lowered.
Check that the sideboards and tailboard are closed and securely latched.
Avoid dropping large items such as rocks, demolition debris etc.
Ensure that the load is uniformly distributed across the Tipper bed.
Do not overhang plank or sheet material forward of the headboard.
WARNING
36
Load Carrying
Load Distribution
CORRECT LOAD DISTRIBUTION
INCORRECT LOAD DISTRIBUTION
37
Load Carrying
Load Retention and Sheeting
The method of load retention will depend on the type of load being carried: -
Fluid loads:
Sheeting the load with a high strength waterproof Tarpaulin is the best form of
retention especially for a dry powdery load. This will prevent the load being blown from
the vehicle and prevent the load becoming waterlogged and thereby potentially
overloading the vehicle.
The body is supplied with roping points at the end of each body cross-bearer under the
floor. These should be used to tie off any Tarpaulins that envelope the body sides.
Once fitted, the Tarpaulin should be restrained by high quality nylon rope, (minimum
12mm Diameter) specifically designed for Commercial Vehicle use.
38
Load Carrying
Load Distribution continued…
Non-fluid loads:
All non-fluid loads must be suitably restrained using the load lashing points provided on
the tipper floor. Loose loads must not be allowed to shift or roll around in the rear of the
vehicle, presenting in some instances, extreme impact forces to the bodysides,
tailboard and headboard, generated by cornering, braking and acceleration forces. If
the load is to be tipped rather than removed mechanically or manually, the lashing
must be removed immediately prior to the tipping operation.
Good quality ratchet straps or approved nylon rope should be used. For cylindrical
loads or awkward shaped loads, it is imperative to chock the load with timber to enable
the straps or rope to work effectively.
Load Lashing Points on Tipper Floor
Do not exceed the maximum front and rear axle loads for your vehicle. Refer
to the Vehicle identification section in the Owner’s Handbook.
WARNING
39
Tipping
Tipping – General Practice
Tipping is a potentially hazardous operation. It is essential that all operators
fully understand the procedures detailed in this handbook and are aware of
the Tipper controls on the vehicle. Health and Safety legislation must be
strictly applied. UK Construction & Use Regulations must be observed when
operating the vehicle on the public highway.
Common Procedures for Tipping:
The following procedures must be observed before, during and after the Tipping
operation.
Before Tipping: -
Apply handbrake.
Switch on hazard warning lights.
Establish that the ground bearing the weight of the vehicle is level and is firm
enough to support the weight of the vehicle. (Maximum gradient 5%). Avoid wet
or waterlogged clay, soil or sandy terrains. If available, have someone direct you to
the required position taking the precautions identified above.
Check that the area surrounding the vehicle is free from personnel, equipment and
livestock, except for an assistant specifically tasked to guide you to the area where
the load is to be tipped. Health and Safety (Safety Signs & Signals Regulations
1996) guidelines on verbal or hand communication must be observed.
WARNING
40
Tipping
Common Procedures for Tipping continued…
Ensure the area surrounding the vehicle is suitably illuminated. (night operation)
Check overhead clearance for overhead cables and power lines, abort tip or
reposition vehicle if there are any overhead cables within the vicinity.
If the load is sheeted, loosen the sheeting; roll back to the headboard and tie-off.
Remove load restraints if fitted.
Now continue with the tipping operation.
During the Tipping operation: -
Be vigilant and observe the operation closely.
Never try to shake a stuck load free, lower body fully to manually remove all or part
of the load. Do not restart tipping until all personnel are clear from the vehicle.
After the load has been Tipped: -
Clean the tipper bed with a broom to clear the floor of debris maintaining the
smooth surface, essential in allowing the load to slip when tipping.
Brush off the body edges and generally clean around the bodyside and / or
tailboard apertures to ensure the side and tailboard can be closed without
jamming.
If used on muddy/dirty sites, always wash down wheels, rear tail-lights, license
plate and lamps before joining the public highway. A potential traffic offence will be
created it the vehicle is driven with obscured lights or license plate.
Perform a visual check for damage.
Re-apply sheeting (if fitted) or fold, roll and store until required.
Switch off hazard warning lights.
41
Tipping
Tipping Load
Method:
Reverse vehicle to the position where you want to tip the load.
Establish which tailboard mode will be used, refer to the Controls section of this
handbook, ensure there is no load pressing against the tailboard.
Tip-Over or Bottom Hinged mode: -
Hold the top of the tailboard with
one hand, with the other hand
use an index finger or forefinger
to release the latch, by first pulling
up to approximately 90 degrees
from the vertical.
Using the palm of your hand push
up on the handle until it is almost
vertical and the latch is released.
Repeat the action for the other latch.
Maintain pressure on the tailboard
until it is safe to lower gently.
42
Tipping
Tipping Load continued…
Tip-Thru or Top Hinged mode: -
Release the lower latch lever by pulling out and towards the front of the vehicle.
Close by pushing the lever rearwards
whilst holding the Tailboard fully closed.
Do not open the lower tailboard latch and the upper tailboard latches at the
same time. The tailboard will fall away from the rear of the vehicle causing
possible injury. Use only the appropriate latch for the tailboard mode required.
WARNING
43
Tipping
Tipping continued…
Switch the Isolation Switch to the ‘ON’ position.
Control the tip using the Tipper Hand Control as described in the controls section
of this manual.
Ideally a visible assistant should be made available to indicate progress of the load
being tipped.
Raise the body to the required height to either tip part or the entire load. The
RAISE button should be released when the ram is fully extended. The tipping can
be stopped at any time by releasing the RAISE button. A buzzer will sound all the
time that the body is raised.
Lower the body until the warning sounder ceases.
If the tip-thru function has been used it is essential that the lower latch jaws are
brushed clean to ensure that the latch doesn't become jammed open by debris.
Close the tailboard observing the precautions outlined in the 'Controls' section,
ensuring that it is securely locked. Use a combination of a visual check around the
lower latch jaws if the tip-thru mode has been used, and a physical tug on the
tailboard to check that they are fully home and locked. Ensure the tailboard release
handles are in the locked position.
Before driving the vehicle, ensure: -
The Isolation Switch is ‘OFF’.
The body is fully lowered.
Check the tailboard is securely latched.
Ensure the rear cross-member, tail-lights, and registration plate are cleared of any
tipped material.
Ensure that all precautions detailed in 'Controls' are observed.
44
Maintenance
Driver Checks and Maintenance Items:
It is imperative that the recommended Driver Checks and Maintenance be
carried out to ensure the safe and efficient operation of the Tipper.
Any maintenance carried out under the load bed must only be performed
when the body is securely propped. Refer to the section Tipper Controls –
Body Prop.
Only competent technical trained personnel should carry out maintenance
involving adjustment or replacement of operating devices on this Tipper.
The driver, regardless of ownership of the vehicle must perform the following checks
and vehicle maintenance. If the driver does not own the vehicle, the owner of the
vehicle must satisfy himself or herself that the driver to whom the vehicle has been
allocated will carry out these essential checks. The driver must be made aware of their
responsibilities to read and understand the Supplementary Tipper Handbook and carry
out the essential Maintenance Checks in line with the maintenance procedure in this
section.
WARNING
CAUTION
45
Maintenance
Daily Driver Checks:
Check the Instruction Manual is complete and located in a safe position within
the cab.
Check the tipper load deck for damage, clean and remove any material that
has stuck to it, ensure the surface is smooth and free from debris that may
snag loads.
Check the security of all side and tailboard latches.
Check the tailboard lower latch mechanism is free from debris and functions
correctly.
Check the rear lights and license plate to ensure any site debris or mud thrown
up from the rear wheels has not obscured them.
46
Maintenance
Monthly Maintenance Checks:
Check operation of warning sounder.
Check the hydraulic lines for signs of fluid leaks.
Check all safety signs are present, and ensure they are legible and not
damaged. (Refer to Spare Parts and Accessories catalogue at www.vfs.co.uk
for details)
Inspect and grease tailboard & sideboard latches with general-purpose grease.
Inspect tailboard lower latch mechanism and apply general-purpose grease to
all mechanism linkage pivot points, including remote operating (yellow) handle
bearing
Ensure the tailboard can close securely without free-play.
47
Maintenance
Annual Maintenance Checks:
In addition to the Monthly Maintenance, the items detailed below should be checked
and adjusted as necessary.
Check the hydraulic reservoir oil level and top up if required with hydraulic oil
ISO 32.
Check the tailboard lower latch mechanism and adjust if necessary.
Check the ‘body stowed’ switch.
Check all electrical cables and ensure that no chaffing has occurred.
Check the Tipper subframe to chassis fixings.
Check the rear corner pillar fixings.
Check the headboard securing fixings.
Check the fender mounting bracket fixings.
Inspect the Tipper deck / subframe and associated components for damage.
Replace or repair locally to maintain Tipper functionality and roadworthiness.
Description Torque Value
(Nm)
Tipper sub-frame to vehicle chassis fixings. 45
Rear corner pillar mounting fixings. 125
Headboard securing fixings. 25
Fender mounting bracket fixings. 25
Side marker lamp mounting bracket fixings (Double Cab
only). 25
48
Maintenance
Checking the Hydraulic Oil Level
Ensure body prop is correctly deployed before attempting to check the
hydraulic reservoir oil level.
Park the vehicle on a firm level surface and apply the handbrake.
Raise the Tipper bed.
Raise the Body Prop by pulling up on the handle.
Rotate the Body Prop past the vertical until it stops.
Lower the body until it stops. Body Prop should be in location cup under bed
floor.
Turn the Tipper Isolation Switch to the 'OFF' position.
Remove the keys from the vehicle ignition.
Visually check the oil level against the Hydraulic Oil Level decal, or unscrew
the oil filler cap and check the oil level on the integral dipstick and if required
top up with hydraulic oil ISO 32.
Replace the oil filler cap and lower the Tipper bed.
Do not top up further than the MAX mark.
WARNING
CAUTION
49
Fuses
Fuses and Fuse Locations
The Tipper electrical system is protected by 3 fuses.
Primary Fuse:
The primary fuse is located inside the battery Compartment. This fuse is a 150A mega
type.
Control Circuit Fuses:
The control circuits are protected by two fuses, 5 Amp and 15Amp. Both are located in
an enclosure mounted on the LH Tipper Subframe.
Do not modify the electrical system of your vehicle in any way. Have repairs
to the electrical system and the replacement of fuses carried out by properly
trained technicians.
Switch ignition and all electrical equipment off before attempting to change a
fuse.
Only fit a replacement fuse with the same rating as the fuse removed.
WARNING
CAUTION
50
Vehicle Care
Cleaning the Exterior
Regular cleaning of the tipper will maintain the smooth surface essential in allowing the
load to slip when tipping. Brush the tipper bed with a broom to clear the floor of debris
and brush off the body edges and generally clean around the bodyside and / or
tailboard apertures to ensure the side and tailboard can be closed without jamming.
If the vehicle has been used on muddy/dirty sites, always wash down the wheels, rear
tail-lights, license plate and lamps.
If the Tipper has been used to transport corrosive material, e.g. road salt. The
Tipper bed and vehicle should be washed as soon as possible, thereby
preventing any potential corrosion.
The use of a high-pressure washer could cause damage to certain parts of
your vehicle.
WARNING
CAUTION
51
Vehicle Care
Repairing Minor Paint Damage
Remove apparently harmless looking substances from the paintwork
immediately (e.g. bird droppings, tree resins, insect remains, tar spots, road
salt and industrial fall out).
You should repair paintwork damage caused by stones from the road or minor
scratches as soon as possible. A choice of products are available from your Dealer.
Read and follow the manufacturer’s instructions.
CAUTION
52
Towing
Do not exceed the maximum vehicle and trailer weight stated on the vehicle
identification plate. Refer to the Vehicle identification section in the Owner’s
Handbook
If a tow bar has been fitted ensure that the tailboard has been installed with a
protective guide to prevent it from jamming on the tow bar/ball/clevis.
Tailboard Protection Plate Assembly Guide
CAUTION
WARNING
53
Fault Finding
Problem Possible Causes Corrective Action
1. The Tipper fails to
operate.
a)
b)
c)
d)
e)
f)
Chassis mounted isolation
switch, switched OFF.
No electrical power (1).
No electrical power (2).
No electrical power (3).
Insufficient hydraulic oil in
the reservoir.
Electric drive motor
defective.
Switch ON isolation switch.
Check fuse in Battery
Compartment (150A).
Check the Tipper Control
fuses 05.0A and 10.0A in
subframe enclosure.
Check all electrical
connections and cables.
Fill the reservoir to the
correct level.
Replace the drive
motor/pump unit.
2. The electric drive
motor runs but the
Tipper fails to rise.
a)
b)
Tipper overloaded.
Hydraulic pump defective.
Reduce load.
Replace the drive
motor/pump unit.
3. Hydraulic oil
sprays from the
reservoir when the
Tipper is lowered.
a)
b)
Reservoir over filled.
Reservoir punctured.
Fill reservoir to the correct
level.
Replace reservoir.
4. Chassis mounted
buzzer fails to
operate.
a)
b)
Buzzer defective.
No electrical power.
Replace buzzer.
See items a - d in 1 above.
5. The Tipper lowers
when the
hydraulic pump
stops.
a)
b)
c)
Defective non-return valve.
Defective pressure release
valve.
Hydraulic oil leak.
Replace non-return valve.
Replace pressure release
valve.
Inspect hydraulic system,
replace parts as required.
54
Fault Finding
Problem Possible Causes Corrective Action
6. Tipper only rises
partially.
a)
b)
c)
d)
Vehicle not on level ground.
Tipper loaded unevenly.
Insufficient oil in the
reservoir.
Pressure relief valve
defective.
Tip when the Tipper is on
level ground.
Redistribute the load.
Fill reservoir to the correct
level.
Replace pressure relief
valve.
7. Tipper fails to
lower.
a)
b)
c)
Solenoid defective.
Solenoid valve defective.
Body fully lowered switch
defective.
Replace solenoid.
Replace solenoid valve.
Replace switch.
55
Lighting
Changing a Bulb
Switch the lights and the ignition off.
Let the bulb cool down before removing it.
Only fit bulbs of the correct specification.
End Outline Marker Lamp (If Fitted):
Carefully prise the lens from the holder.
Gently press the bulb into the bulb holder, turn it anti-clockwise and remove.
Replacement bulb type: BA15s 12V 5W
Side Marker Lamp (Double Cab Only):
Disconnect the electrical connector.
Turn the bulb holder anti-clockwise and remove it.
Remove the bulb.
Replacement bulb type: W2.1 x 9.5d 12V 5W
WARNING
CAUTION
56
Vehicle Identification
Tipper Body Type and Serial Number:
The Tipper Body Type and Serial Number information is stamped on the Tipper ID
plate, this is riveted to the left hand side subframe member.
57
Technical Specifications
Vehicle Dimensions:
Medium Wheelbase Single Cab
58
Technical Specifications
Vehicle Dimensions:
Long Wheelbase Double Cab
